Suturing instrument with robotic drive interface

ABSTRACT

A surgical instrument includes cartridge receiving assembly, a shaft assembly, and an interface assembly. The cartridge receiving assembly is operable to receive a needle driving cartridge. The shaft assembly includes a first actuation member that is operable to actuate the cartridge receiving assembly to thereby drive a needle from a needle driving cartridge received in the cartridge receiving assembly. The interface assembly includes a base and a plurality of drive shafts extending upwardly from the base. The drive shafts extend along respective axes that are perpendicular to the longitudinal axis of the shaft assembly. The drive shafts are rotatable independently relative to each other. A first drive shaft of the plurality of drive shafts is operable to drive the first actuation member. The interface assembly is configured to couple with a robotic control system.

BACKGROUND

Sutures may be used in a wide variety of surgical procedures. Manualsuturing may be accomplished by the surgeon using a fine pair ofgraspers to grab and hold a suture needle, pierce the tissue with theneedle, let go of the needle, and re-grasp the needle to pull the needleand accompanying suture thread through the tissues to be sutured. Suchneedles may be curved with the suture attached to the trailing end ofthe needle.

Some surgical instruments automate at least part of the suturingprocedure. Examples of automated suturing instruments are described inU.S. Pat. No. 8,702,732, entitled “Laparoscopic Suturing Instrument withDual-Action Needle Graspers,” issued Apr. 22, 2014, the disclosure ofwhich is incorporated by reference herein; U.S. Pub. No. 2011/0313433,entitled “Laproscopic Suture Device with Asynchronous In-Line NeedleMovement,” published Dec. 22, 2011, now U.S. Pat. No. 9,168,037, issuedOct. 27, 2015, the disclosure of which is incorporated by referenceherein; U.S. Pub. No. 2014/0171970, entitled “Circular Needle Applierwith Articulating and Rotating Shaft,” published Jun. 19, 2014, now U.S.Pat. No. 9,357,998, issued Jun. 7, 2016, the disclosure of which isincorporated by reference herein; and U.S. patent application Ser. No.14/297,993, entitled “Jawed Cartridge receiving assembly for NeedleCartridge,” filed Jun. 6, 2014, now U.S. Pat. No. 9,474,522, issued Oct.25, 2016, the disclosure of which is incorporated by reference herein.

Some surgical systems provide robotic control of a surgical instrument.With minimally invasive robotic surgery, surgical operations may beperformed through a small incision in the patient's body. A roboticsurgical system may be used with various types of surgical instruments,including but not limited to surgical staplers, ultrasonic instruments,electrosurgical instruments, suturing instruments, and/or various otherkinds of instruments, as will be described in greater detail below. Anexample of a robotic surgical system is the DAVINCI™ system by IntuitiveSurgical, Inc., of Sunnyvale, Calif. By way of further example, one ormore aspects of robotic surgical systems are disclosed in the following:U.S. Pat. No. 5,792,135, entitled “Articulated Surgical Instrument ForPerforming Minimally Invasive Surgery With Enhanced Dexterity andSensitivity,” issued Aug. 11, 1998, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 5,817,084, entitled“Remote Center Positioning Device with Flexible Drive,” issued Oct. 6,1998, the disclosure of which is incorporated by reference herein; U.S.Pat. No. 7,524,320, entitled “Mechanical Actuator Interface System forRobotic Surgical Tools,” issued Apr. 28, 2009, the disclosure of whichis incorporated by reference herein; U.S. Pub. No. 2012/0132450,entitled “Shiftable Drive Interface for Robotically-Controlled SurgicalTool,” published May 31, 2012, now U.S. Pat. No. 8,616,431, issued Dec.31, 2013, the disclosure of which is incorporated by reference herein;and U.S. Pub. No. 2012/0298719, entitled “Surgical Stapling Instrumentswith Rotatable Staple Deployment Arrangements,” published Nov. 29, 2012,now U.S. Pat. No. 9,072,535, issued Jul. 7, 2015, the disclosure ofwhich is incorporated by reference herein.

While various kinds of suturing instruments and associated componentshave been made and used, it is believed that no one prior to theinventor(s) has made or used the invention described in the appendedclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims which particularly pointout and distinctly claim this technology, it is believed this technologywill be better understood from the following description of certainexamples taken in conjunction with the accompanying drawings, in whichlike reference numerals identify the same elements and in which:

FIG. 1 depicts a side view of an exemplary surgical suturing instrument;

FIG. 2A depicts top perspective exploded view of a cartridge receivingassembly of the instrument of FIG. 1;

FIG. 2B depicts bottom perspective exploded view of the cartridgereceiving assembly of FIG. 2A;

FIG. 3A depicts a top perspective view of an exemplary cartridgeconfigured for receipt in the cartridge receiving assembly of FIG. 2A;

FIG. 3B depicts a bottom perspective view of the cartridge of FIG. 3A;

FIG. 4 depicts an exploded view of the cartridge of FIG. 3A;

FIG. 5A depicts a perspective view of a drive assembly of the cartridgeof FIG. 3A, with the drive assembly at one end of its stroke;

FIG. 5B depicts a perspective view of the drive assembly of FIG. 5A,with the drive assembly at mid-stroke;

FIG. 5C depicts a perspective view of the drive assembly of FIG. 5A,with the drive assembly at the other end of its stroke;

FIG. 6 depicts a partial plan view of a needle driver of the cartridgeof FIG. 3A engaging a needle of the cartridge of FIG. 3A;

FIG. 7 depicts a perspective view of an exemplary robotic system driveinterface assembly that may be incorporated into the instrument of FIG.1 in place of the handle assembly;

FIG. 8 depicts another perspective view of the drive interface assemblyof FIG. 7;

FIG. 9 depicts a top plan view of the drive interface assembly of FIG.7;

FIG. 10 depicts a bottom plan view of the drive interface assembly ofFIG. 7;

FIG. 11 depicts a perspective view of the drive interface assembly ofFIG. 7, with shaft rotation drive components shown exploded from therest of the drive interface assembly;

FIG. 12 depicts a perspective view of a first drive gear member of theshaft rotation drive components of FIG. 11;

FIG. 13 depicts a perspective view of a second drive gear member of theshaft rotation drive components of FIG. 11;

FIG. 14A depicts a perspective view of the cartridge receiving assemblyof FIG. 2A, the cartridge of FIG. 3A, and a shaft assembly of the driveinterface assembly of FIG. 7, all in a first angular position about thelongitudinal axis of the shaft assembly;

FIG. 14B depicts a perspective view of the cartridge receiving assemblyof FIG. 2A, the cartridge of FIG. 3A, and the shaft assembly of thedrive interface assembly of FIG. 7, with an outer sheath and anarticulation joint of the shaft assembly driven to a second angularposition about the longitudinal axis of the shaft assembly by the shaftrotation drive components of FIG. 11, while the cartridge receivingassembly of FIG. 2A and the cartridge of FIG. 3A remain in the firstangular position;

FIG. 15 depicts a perspective view of the drive interface assembly ofFIG. 7, with cartridge receiving assembly rotation drive componentsshown exploded from the rest of the drive interface assembly;

FIG. 16 depicts a perspective view of the distal end of a drive shaft ofthe cartridge receiving assembly rotation drive components of FIG. 15coupled with the cartridge receiving assembly of FIG. 2A;

FIG. 17A depicts a perspective view of the cartridge receiving assemblyof FIG. 2A, the cartridge of FIG. 3A, and the shaft assembly of thedrive interface assembly of FIG. 7 all in a first angular position aboutthe longitudinal axis of the shaft assembly;

FIG. 17B depicts a perspective view of the cartridge receiving assemblyof FIG. 2A and the cartridge of FIG. 3A both driven to a second angularposition about the longitudinal axis of the shaft assembly by thecartridge receiving assembly rotation drive components of FIG. 15, whilethe shaft assembly remains in the first angular position;

FIG. 18 depicts a perspective view of the drive interface assembly ofFIG. 7, with needle drive components shown exploded from the rest of thedrive interface assembly;

FIG. 19 depicts a perspective view of the drive interface assembly ofFIG. 7, with articulation drive components shown exploded from the restof the drive interface assembly;

FIG. 20 depicts a perspective view of a gear member of the articulationdrive components of FIG. 19;

FIG. 21 depicts a perspective view of a proximal end of an articulationdrive rod of the articulation drive components of FIG. 19;

FIG. 22A depicts the gear member and articulation drive rods of thearticulation drive components of FIG. 19 in a first configuration;

FIG. 22B depicts the gear member and articulation drive rods of thearticulation drive components of FIG. 19 in a second configuration;

FIG. 22C depicts the gear member and articulation drive rods of thearticulation drive components of FIG. 19 in a third configuration;

FIG. 23A depicts a top plan view of the cartridge receiving assembly ofFIG. 2A, the cartridge of FIG. 3A, and the shaft assembly of the driveinterface assembly of FIG. 7, with the cartridge receiving assemblyaligned with the longitudinal axis of the shaft assembly;

FIG. 23B depicts a top plan view of the cartridge receiving assembly ofFIG. 2A, the cartridge of FIG. 3A, and the shaft assembly of the driveinterface assembly of FIG. 7, with the cartridge receiving assemblydeflected in a first direction away from the longitudinal axis of theshaft assembly by the articulation drive components of FIG. 19; and

FIG. 23C depicts a top plan view of the cartridge receiving assembly ofFIG. 2A, the cartridge of FIG. 3A, and the shaft assembly of the driveinterface assembly of FIG. 7, with the cartridge receiving assemblydeflected in a second direction away from the longitudinal axis of theshaft assembly by the articulation drive components of FIG. 19.

The drawings are not intended to be limiting in any way, and it iscontemplated that various embodiments of the technology may be carriedout in a variety of other ways, including those not necessarily depictedin the drawings. The accompanying drawings incorporated in and forming apart of the specification illustrate several aspects of the presenttechnology, and together with the description serve to explain theprinciples of the technology; it being understood, however, that thistechnology is not limited to the precise arrangements shown.

DETAILED DESCRIPTION

The following description of certain examples of the technology shouldnot be used to limit its scope. Other examples, features, aspects,embodiments, and advantages of the technology will become apparent tothose skilled in the art from the following description, which is by wayof illustration, one of the best modes contemplated for carrying out thetechnology. As will be realized, the technology described herein iscapable of other different and obvious aspects, all without departingfrom the technology. Accordingly, the drawings and descriptions shouldbe regarded as illustrative in nature and not restrictive.

I. Overview of Exemplary Surgical Suturing Instrument

FIG. 1 illustrates an example of a surgical suturing instrument (2).Instrument (2) comprises a handle assembly (10), an elongate shaft (20),and a cartridge receiving assembly (50), which is operable to receive aneedle applier cartridge (30). Shaft (20) has a proximal end (21), adistal end (22), and a longitudinal axis extending therebetween. Handleassembly (10) is connected to the proximal end (21) of the shaft (20).In this example handle assembly (10) is a manual pistol grip handle.However, a variety of other manual actuators could also be used,including but not limited to a scissor grip handle, a syringe griphandle, endoscopic rotary knobs, and the like. Handle assembly (10)could also take the form of a robotic interface, such as a DAVINCI puck,or a housing comprising gears or pulleys, servomechanisms, and the like.

Needle applier cartridge (30) is connected to the distal end (22) ofshaft (20) via cartridge receiving assembly (50). Needle appliercartridge (30) is operable to rotate an arced needle in a circular pathenabling a surgeon to selectively apply sutures. In some alternativeversions, needle applier cartridge (30) is integral with shaft (20) andhandle assembly (10) as a unitary disposable instrument intended for asingle surgical procedure. Needle applier cartridge (30) may also beintegral with shaft (20) and handle assembly (10) as a reusableinstrument. Optionally, as illustrated here, needle applier cartridge(30) may be provided in a disposable cartridge body (90) and shaft (20)includes cartridge receiving assembly (50) to releasably hold cartridgebody (90). In some such versions, shaft (20) and handle assembly (10)may also be disposable or reusable. Versions with reusable componentsare intended to be cleaned, sterilized, and reused for a multiplesurgical procedures, and may include a flush port (18) to facilitatecleaning. The preferable life cycle of a reusable instrument is at least50 operations, more preferably at least 150 operations, and mostpreferably at least 200 operations. Reusable components may be builtusing materials that can withstand autoclave sterilization temperaturesof at least 135 degrees Celsius, although low temperature materials canalso be used with low temperature sterilization techniques known in theart.

A first input (12), shown here as a trigger that pivots between openedand closed positions, may be used to selectively actuate needle appliercartridge (30). The trigger may be spring biased to return the triggerto its open position. A second input (14), shown here as a rotary knob,may be used to selectively articulate shaft (20). A third input (16),shown here as a rotary knob, may be used to selectively rotate needleapplier cartridge (30) about shaft (20). Of course, the number, type,configuration, and operation of inputs (12, 14, 16) may vary.

FIGS. 2A-2B illustrate exploded views of cartridge receiving assembly(50) of the present example. Distal end (22) of shaft (20) comprises anarticulation joint (23) and a rotational bearing (24). Articulationjoint (23) includes a knuckle (23A) that receives pins (23B, 23C), whichare connected to bearing supports (24B, 24C). Thus, pins (23B, 2C)define the pivoting axis for articulation joint (23), enabling cartridgereceiving assembly (50) to articulate left and right relative the shaft(20), away from the longitudinal axis defined by shaft (20). Rods (27A,27B) are operably connected to articulation joint (23). In this example,rods (27A, 27B) extend through shaft (20), through knuckle (23A), andconnect to pins (29A, 29B) on bearing support (24C). Rods (27A, 27B) areoperatively connected to second input (14) to opposingly push and pullrods (27A, 27B). In other words, second input (14) is operable to driverods (27A, 27B) at the same time in opposite longitudinal directions,such that rod (27A) will translate distally while rod (27B) translatesproximally; and such that rod (27B) will translate distally while rod(27A) translates proximally. Because pins (29A, B) are laterally spacedfrom the pivoting axis, the simultaneous push and pull action will inturn articulate cartridge receiving assembly (50) about joint (23)relative to shaft (20).

Rotational bearing (24) is positioned distal to articulation joint (23).Bearing (24) includes a circumferential flange (24A) that is capturedbetween the bearing supports (24B, 24C) such that the flange (24A) canrotate relative the bearing supports (24B, 24C) and enabling unboundedrotation of cartridge receiving assembly (50) relative shaft (20) aboutthe longitudinal axis defined by shaft (20). A drive rod (28) extendsthrough shaft (20). In this example, drive rod (28) comprises a proximalrigid portion (28A) and a distal bendable portion (28B) that are fixedlyconnected to one another. Bendable portion (28B) extends througharticulation joint (23) and through bearing (24); distal end (28C) isfixedly connected to a mount (49) on a rack (45).

Rack (45) reciprocates longitudinally in lower jaw (51) with followers(45A, 45B, 45C, 45D) constrained in tracks (55A, 55B, 55C, 55D),respectively. Tracks (55A, 55B, 55C, 55D) open through lower jaw (51),providing fluid passages to the internal components within the lower jaw(51), thus facilitating easier cleaning. A pinion (47) is mounted tolower jaw (51) by the pin (46) in the rack (45) such that longitudinalreciprocation of the rack (45) is converted into rotationalreciprocation of pinion (47). A key (48) communicates the reciprocatingrotation to a rotary input (94) in cartridge body (90), which in turnactuates needle applier cartridge (30).

Drive rod (28) is operatively connected to first input (12) and to thirdinput (16). Actuation of first input (12) will impart axial push andpull loads on drive rod (28) to longitudinally reciprocate rack (45) andthereby actuate needle applier cartridge (30). Actuation of third input(16) will impart a rotational load on drive rod (28) thus rotatingcartridge receiving assembly (50) about bearing (24) relative to shaft(20). Accordingly, a single drive rod (28) operates to both actuateneedle applier cartridge (30) as well as control distal rotation ofneedle applier cartridge (30) about the longitudinal axis of shaft (20).By consolidating dual functions with a single drive rod (28), the numberof components is reduced, and more space is provided in the shaft (20),which may make the device less expensive to manufacture and easier toclean.

Cartridge receiving assembly (50) is dimensioned and adapted to receiveand hold cartridge body (90). As shown in FIGS. 2A-2B, cartridgereceiving assembly (50) of this example has upper and lower jaws (56,51) that are operable to transition between an open configuration and aclosed configuration. In the closed configuration, jaws (56, 51) areoperable to receive and retain cartridge body (90). In the openconfiguration, jaws (56, 51) are operable to release cartridge body(90). In the present example, lower jaw (51) is stationary and upper jaw(56) pivots. Alternatively, the arrangement could be reversed, or insome versions both jaws (56, 51) could pivot. Lower jaw (51) has twolaterally offset longitudinal rails (52) that are dimensioned andadapted to receive cartridge body (90). Rails (52) help longitudinallyalign cartridge body (90) in cartridge receiving assembly (50) andlaterally retain cartridge body (90) in jaws (51, 56). Upper jaw (56)pivots relative lower jaw (51) about a pin (53) that is received inholes (57). A tooth (59) is resiliently oriented downwardly from upperjaw (56) toward lower jaw (51) with a ramped distal face and a steppedproximal face. Tooth (59) is dimensioned and adapted to latch withcartridge body (90) and longitudinally retain cartridge body (90) injaws (51, 56). Tooth (59) deflects by virtue of a resilient cantileveredarm extending proximally from the distal end of upper jaw (56). In thisexample, tooth (59) and the cantilevered arm are monolithic with upperjaw (56), thus reducing the number of components and moving pieces,which may make the device less expensive to manufacture and easier toclean.

A button (60) is operable to open and close jaws (51, 56). While button(60) could be placed on or near the handle assembly (10) in someversions, in this example button (60) is positioned adjacent cartridgereceiving assembly (50), which eliminates a linkage in shaft (20) thuscreating space in shaft (20) and making the device less expensive andeasier to clean. The action of button (60) may vary, but in this examplebutton (60) pivots relative to lower jaw (51) about a pin (63) that isreceived hole (61). A follower (62) is received by cam slots (54, 58).Pivoting button (60) proximally will open jaws (51, 56), while pivotingbutton (60) distally will close jaws (51, 56). A spring (64) engages andbiases button (60) distally. By pulling button (60) proximally, follower(62) will drive cam slot (58) to open upper jaw (56). When button (60)is released, spring (64) will resiliently drive button (60) distally toclose upper jaw (56).

FIGS. 3A-3B illustrate cartridge body (90) of the present example ingreater detail. A lower face (91) of cartridge body (90) is adapted toengage lower jaw (51); and an upper face (96) to engage upper jaw (56).Poke-yoke features on cartridge body (90) prevent improper insertion ofcartridge body (90) into cartridge receiving assembly (50), but alsocontribute to the aesthetic appearance of cartridge body (90). Forinstance, lower face (91) has a pair of longitudinal notched shoulders(92) that are dimensioned to interface and mate with rails (52). In thisexample, notched shoulders (92) are shaped as a stepped rabbet, but avariety of other aesthetic shapes could also be employed such aschamfers and radii. In contrast, upper face (96) is asymmetricalrelative lower face (91) and lacks shoulder notches, so upper face (96)would interfere with rails (52) if cartridge body (90) were insertedupside-down in cartridge receiving assembly (50). In another instance,the geometry of a proximal face (98) of cartridge body (90) isvertically asymmetrical and thus prevents cartridge body (90) from beinginserted upside-down between jaws (51, 56). In this example, proximalface (98) comprises a curved surface that gently transitions to upperface (96), which matches similar geometry in cartridge receivingassembly (50); while the transition to lower face (91) has a tighterradius. Of course, a variety of other asymmetrical aesthetic geometriescould also be employed that could contribute to the visual appearanceand/or poke-yoke aspects of cartridge body (90).

Arms (93A, 93B) define a generally U-shaped distal end on cartridge body(90). A slot (95) and rotary input (94) are aligned and dimensioned toreceive the key (48) while cartridge body (90) is being slid intocartridge receiving assembly (50). When cartridge body (90) is fullyseated into cartridge receiving assembly (50), a step (99) aligns withand receives tooth (59) to latch cartridge body (90) in cartridgereceiving assembly (50). Key (48) also aligns with rotary input (94),thereby providing a torsional interface that rotationally couples pinion(47) and rotary input (94). In use, the needle (70) exits arm (93A) andenters arm (93B).

As shown in FIGS. 3A-4, cartridge body (90) further comprises a lowerbody (81), an upper body (82), a needle (70), and a needle cover (83).Needle driver (86), rotary input (94), and a link (85) are capturedbetween lower body (81) and upper body (82). Bodies (81, 82) may beattached to one another using a variety of known techniques, includingwelds, pins, adhesives, and the like to form cartridge body (90). Needle(70) has a leading end (71) and a length of suture (73) extending fromthe trailing end (72). Needle (70) orbits in a circular path defined bya needle track (84) and between arms (93A, 93B). Needle (70) includesnotches (74) that are configured to facilitate engagement between needledriver (86) and needle (70). Needle (70) is captured in needle track(84) by needle cover (83). A cage (87) slides over bodies (81, 82) andneedle cover (83) to attach needle cover (83) against lower body (81).

FIGS. 5A-5C illustrate an example of a drive stroke of the transmissionin cartridge body (90) for driving needle (70) in a circular, orbitalpath. However, it should be understood that needle (70) and suture (73)omitted from FIGS. 5B-5C. Needle driver (86) rides in a carrier track(88) and extends into needle track (84) to engage and drive needle (70).A link (85) connects rotary input (94) to needle driver (86). FIG. 5Ashows needle driver (86) positioned at one end of its stroke in carriertrack (88). As shown in FIG. 5B, counterclockwise rotation of rotaryinput (94) will translate needle driver (86) clockwise along carriertrack (88), thereby driving needle (70) clockwise. As shown in FIG. 5C,continued counterclockwise rotation of the rotary input (94) willcontinue to translate needle driver (86) and thereby drive needle (70)clockwise until it reaches the other end of its stroke in carrier track(88). In this example, the drive stroke rotates the needle (70) in itscircular path along an angular range of about 180 degrees. For thereturn stroke, the sequence can be reversed by rotating the rotary input(94) clockwise, which will translate needle driver (86) counterclockwisein carrier track (88). Needle driver (86) is disengaged from needle (70)during the return stroke until needle driver (86) reaches the end of thereturn stroke. Needle driver (86) will re-engage needle (86) uponcompleting the return stroke. Thus, a sequence of drive and returnstrokes will rotate the needle (70) in a circular path.

FIG. 6 illustrates a detailed view of needle driver (86) engaging needle(70).

Needle driver (86) comprises a carrier (86A) and a driver (86B). Carrier(86A) is dimensioned to slideably fit in carrier track (88). Driver(86B) is attached to carrier (75) and is operative to engage needle (70)at an oblique angle. Leftward movement of needle driver (86) will causedriver (86B) to engage proximal notch (74) of needle (70) during thedrive stroke. When so engaged, needle (70) will slide in needle track(84) in unison with needle driver (86). Due to the oblique angle,rightward movement of needle driver (86) will disengage driver (86B)from proximal notch (74) of needle (70) and slide over the stationaryneedle (70) during the return stroke.

Referring back to FIGS. 5A-5C, when first input (12) is depressed,closing the trigger, needle driver (86) will be actuated through itsdrive stroke where it orbits along an angular range of motion at leastabout 180 degrees counterclockwise to a driven position as shown in FIG.5C. During the drive stroke, driver (86B) engages proximal notch (74)and will in unison rotate needle (70) about 180 degrees along an orbitalpath to its extended position. Needle (70) will span across arms (93A,93B) between exit port (95) and entrance port (97). Tissue interposedbetween arms (93A, 93B) will be pierced by leading end (71) of needle(70).

When first input (12) is released and the spring return opens thetrigger, needle driver (86) reciprocates through its return stroke whereit orbits along an angular range of motion about 180 degrees clockwiseback to the return position shown in FIG. 5A. During the return stroke,driver (86B) slides over the needle (70). Driver (86B) is then adjacentthe distal notch (74). When first input (12) is depressed again closingthe trigger, needle driver (86) will again be actuated through its drivestroke where it orbits along an angular range of motion about 180degrees counterclockwise to the driven position as shown in FIG. 5C.During the drive stroke, driver (86B) engages distal notch (74) and willin unison drive needle (70) orbitally along an angular range of motionabout 180 degrees back to its retracted position. Suture (73) willfollow needle (70) and be threaded through the pierced tissue.

When first input (12) is again released and the spring return opens thetrigger, needle driver (86) again reciprocates through its return strokewhere it orbits along an angular range of motion about 180 degreesclockwise back to its returned position as shown in FIG. 5A. During thereturn stroke, driver (86B) slides over needle (70). Thus, needle (70)is driven in a complete circular path spanning an angular range of 360°in response to first input (12) being actuated twice. The sequence maybe repeated as needed by the surgeon to achieve the desired suturingtask.

Further details, explanations, examples, and alternative embodiments ofsurgical suturing devices and subcomponents of the foregoing aredisclosed in U.S. Pub. No. 2014/0171970, entitled “Circular NeedleApplier with Articulating and Rotating Shaft,” published Jun. 19, 2014,now U.S. Pat. No. 9,357,998, issued Jun. 7, 2016, the disclosure ofwhich is incorporated by reference herein; U.S. patent application Ser.No. 14/297,993, entitled “Jawed Cartridge Receiving Assembly for NeedleCartridge,” filed Jun. 6, 2014, now U.S. Pat. No. 9,474,522, issued Oct.25, 2016, the disclosure of which is incorporated by reference herein;and U.S. patent application Ser. No. 14/298,038, entitled “CircularNeedle Applier with Cleats,” filed Jan. 30, 2015, now U.S. Pat. No.9,375,212, issued Jun. 28, 2016, the disclosure of which is incorporatedby reference herein. It should be understood that such details,explanations, examples, and alternative embodiments may be readilyapplied to the above-described instrument (10) and subcomponentsthereof.

II. Exemplary Robotic Drive Assembly Interface for Suturing Instrument

A. Overview

In some instances, it may be beneficial to modify surgical suturinginstrument (2) described above with elements that will enable instrumentto be controlled robotically. For example, it may be beneficial tomodify or replace handle assembly (10) with an interface that isconfigured to couple with a robotic control system. Thus, instead ofutilizing inputs (12, 14, 16), which may be more suitable for handheldcontrol of surgical suturing instrument (2), alternate input controlsmay be utilized for robotic control. The following description relatesto an assembly that is configured to interface with a robotic controlsystem like a system as described in U.S. Pat. No. 5,792,135; U.S. Pat.No. 5,817,084; U.S. Pat. No. 7,524,320; U.S. Pub. No. 2012/0132450, nowU.S. Pat. No. 8,616,431; and/or U.S. Pub. No. 2012/0298719, now U.S.Pat. No. 9,072,535, the disclosures of which are incorporated byreference herein. However, it should be understood that the followingteachings may be readily modified to enable the assembly to interfacewith other kinds of robotic control systems.

FIGS. 7-10 show multiple views of an assembled robotic drive assemblyinterface (100) for a suturing instrument like instrument (2) describedabove. It should be understood that instrument (2) may readilyincorporate drive assembly interface (100) in place of handle assembly(10). Drive assembly interface (100) comprises a base (116) defining aplurality of apertures (110), a mounting plate (114) configured to mountto a robotic arm (not shown), a shaft support structure (122), fourdrive discs (120 a, 120 b, 120 c, 120 d), a sheath rotation drive (200),a cartridge receiving assembly rotation drive (300), a needle drive(400), and an articulation drive (500).

A shaft assembly (150) extends distally from drive assembly interface(100). Shaft assembly (150) comprises an outer sheath (234) and othermovable drive components as will be described in greater detail below.Shaft support structure (122) extends upwardly from base (116) andprovides support to outer sheath (234) (while still allowing outersheath (234) to rotate). By way of example only, shaft support structure(122) may include a bushing, bearings, and/or other features thatfacilitate rotation of outer sheath (234) relative to support structure(122).

As shown in FIG. 10, base (114) further includes four drive discs (120a, 120 b, 120 c, 120 d) that are rotatable relative to plate (116). Eachdisc (120) includes a pair of unitary pins (121) that couple withcomplementary recesses (not shown) in drive elements of robotic arm (notshown). In some versions, one pin (121) of each pair is closer to theaxis of rotation of the corresponding disc (120 a, 120 b, 120 c, 120 d),to ensure proper angular orientation of disc (120 a, 120 b, 120 c, 120d) relative to the corresponding drive element of robotic arm (notshown). As best seen in FIGS. 7-8, a drive shaft (250, 350, 450, 550)extends unitarily upwardly from each disc (120 a, 120 b, 120 c, 120 d).As will be described in greater detail below, discs (120 a, 120 b, 120c, 120 d) are operable to provide independent rotation of sheathrotation drive (200), cartridge receiving assembly rotation drive (300),need drive (400), and articulation drive, through independent rotationof drive shafts (250, 350, 450, 550).

B. Exemplary Shaft Assembly Rotation Drive Components

As shown in FIG. 11, sheath rotation drive (200) includes drive disc(120 a), drive shaft (250), a first rotary member (210), an idler member(220), and a second rotary member (230). As best seen in FIG. 13, firstrotary member (210) comprises a first bevel gear (212) unitarily fixedto a coupling shaft (214). Referring back to FIG. 11, coupling shaft(214) extends through aperture (110). First bevel gear (212) andcoupling shaft (214) together define a bore (211). However, it should benoted that coupling shaft (214) alone may define bore (211). Bore (211)is dimensioned to receive drive shaft (250) through an interference fitso that first rotary member (210) and drive shaft (250) are unitarilyfixed together. Of course, any other means of fixing drive shaft (250)to first rotary member (210) may be used, such as welding. It should beunderstood that rotation of drive disc (120 a) also provides rotation todrive shaft (250) and first bevel gear (212).

As best seen in FIG. 12, idler member (220) includes a second bevel gear(222) and a first spur gear (223) unitarily fixed to each other by acoupling shaft (224). Therefore, rotation of second bevel gear (222)unitarily rotates first spur gear (223). Idler member (220) rotatablyrests on a pair of legs (240, 245) extending above base plate (116). Insome versions, idler member (220) is rotatably secured to legs (240,245) by a bushing, bearings, and/or other features that facilitaterotation of idler member (220) relative to legs (240, 245). Legs (240,245) extend from base plate (116) to a height allowing second bevel gear(222) to mesh with first bevel gear (212). Thus, rotation of first bevelgear (212) of first rotary member (210) provides rotation for secondbevel gear (222) and first spur gear (223) of idler member (220).

It should be understood that rotation of first bevel gear (212) about afirst axis defined by drive shaft (250) is converted into rotation ofsecond bevel gear (222) about a second axis, which is orthogonal to thefirst axis and parallel with the longitudinal axis (LA) of shaftassembly (150). A clockwise (CW) rotation of second bevel gear (222)results in CW rotation of first spur gear (223). A counter-clockwise(CCW) rotation of second bevel gear (222) results in CCW rotation offirst spur gear (223). Other suitable ways in which idler member (220)may be rotated will be apparent to those of ordinary skill in the art inview of the teachings herein.

Second rotary member (230) includes a second spur gear (232) and anelongated outer sheath (234), where both second spur gear (232) andelongated outer sheath (234) define a hollow portion (231). Second spurgear (232) is unitarily coupled to elongated outer sheath (234).Therefore, rotation of second spur gear (232) unitarily rotateselongated outer sheath (234). Legs (240, 245) also extend from baseplate (116) to a height allowing first spur gear (223) to mesh withsecond spur gear (232). Thus, rotation of first spur gear (223) of idlermember (220) provides rotation for second spur gear (232) of secondrotary member (230). It should be understood that rotation of first spurgear (223) about second axis is converted into rotation of second spurgear (232) about longitudinal axis (LA) parallel with second axis. A CWrotation of first spur gear (223) results in CCW rotation of second spurgear (232). A CCW rotation of first spur gear (223) results in CWrotation of second spur gear (232). Other suitable ways in which secondrotary member (230) may be rotated will be apparent to those of ordinaryskill in the art in view of the teachings herein.

Elongated outer sheath (234) extends along the longitudinal axis (LA) ofshaft assembly (150). Elongated outer sheath (234) is substantiallysimilar to elongated shaft (20) as mentioned above. Therefore, as can beseen in FIGS. 14A-14B, distal end of elongated outer sheath (234) isfixed to knuckle (23A) of articulation joint (23). As mentioned above,knuckle (23A) is coupled to bearing supports (24B, 24C). Bearingsupports (24B, 24C) allow circumferential flange (24A) to rotaterelative to bearing supports (24B, 24C). Also as mentioned above,circumferential flange (24A) is capable of rotating cartridge receivingassembly (50). Therefore, rotation of elongated outer sheath (234) doesnot rotate circumferential flange (24A) or cartridge receiving assembly(50). However, rotation of elongated outer sheath (234) will rotatearticulation joint (23).

FIGS. 14A-14B show the ultimate result of rotating drive disc (120 a) ofsheath rotation drive (200). Rotation of drive disc (120 a) rotatesdrive shaft (250) and first bevel gear (212). Rotation of first bevelgear (212) in turn rotates second bevel gear (222) and first spur gear(223) in the same direction and about the same axis. First spur gear(223) then rotates second spur gear (232) about a separate, parallelaxis in the opposite angular direction. Elongated outer sheath (234)rotates about the same axis and same direction of second spur gear(232), thereby rotating articulation joint (23) about the longitudinalaxis (LA) defined by shaft assembly (150). Such rotation may enable theoperator to position articulation joint (23) at a preferred angularorientation, before or after articulation joint (23) is transitioned toan articulated state.

C. Exemplary Cartridge Receiving Assembly Rotation Drive Components

As shown in FIG. 15, cartridge receiving assembly rotation drive (300)includes drive disc (120 b), drive shaft (350), a first rotary member(310), an idler member (320), and a second rotary member (330). Firstrotary member (310) is configured substantially identical to firstrotary member (210) as described above and as best shown in FIG. 13. Inparticular, first rotary member (310) comprises a first bevel gear (312)unitarily fixed to a coupling shaft (314). Coupling shaft (314) extendsthrough aperture (110). First bevel gear (312) and coupling shaft (314)together define a bore (311). However, it should be noted that couplingshaft (314) alone may define bore (311). Bore (311) is dimensioned toreceive drive shaft (350) through an interference fit so that firstrotary member (310) and drive shaft (350) are unitarily fixed together.Of course, any other means of fixing drive shaft (250) to first rotarymember (210) may be used, such as welding. It should be understood thatrotation of drive disc (120 b) also provides rotation to drive shaft(350) and first bevel gear (312).

Idler member (320) is configured substantially identical to idler member(220) as described above and as best shown in FIG. 12. In particular,idler member (320) includes a second bevel gear (322) and a first spurgear (323) unitarily fixed to each other by a coupling shaft (324).Therefore, rotation of second bevel gear (322) unitarily rotates firstspur gear (323). Idler member (320) rotatably rests on a pair of legs(340, 345) extending above base plate (116). In some versions, idlermember (320) is rotatably secured to legs (340, 345) by a bushing,bearings, and/or other features that facilitate rotation of idler member(320) relative to legs (340, 345). Legs (340, 345) extend from baseplate (116) to a height allowing second bevel gear (322) to mesh withfirst bevel gear (312). Thus, rotation of first bevel gear (312) offirst rotary member (310) provides rotation for second bevel gear (322)and first spur gear (323) of idler member (320).

It should be understood that rotation of first bevel gear (312) about athird axis defined by drive shaft (350) is converted into rotation ofsecond bevel gear (322) about a fourth axis that is orthogonal withthird axis and parallel with the longitudinal axis (LA) of shaftassembly. A CW rotation of second bevel gear (322) results is CWrotation of first spur gear (323). A counter-clockwise (CCW) rotation ofsecond bevel gear (322) results in CCW rotation of first spur gear(323). Other suitable ways in which idler member (320) may be rotatedwill be apparent to those of ordinary skill in the art in view of theteachings herein.

Second rotary member (330) includes a second spur gear (332) and arotational shaft (334), where both second spur gear (332) and rotationalshaft (334) define a hollow portion (331). Rotational shaft (334)extends coaxially through elongated outer sheath (234) and rotatesindependently of elongated outer sheath (234). Rotational shaft (334)thus extends along the longitudinal axis (LA) of shaft assembly (150)and is rotatable about the longitudinal axis (LA) of shaft assembly(150). Second spur gear (332) is unitarily coupled to rotational shaft(334). Therefore, rotation of second spur gear (332) unitarily rotatesrotational shaft (334). Legs (340, 345) also extend from base plate(116) to a height allowing first spur gear (323) to mesh with secondspur gear (332). Thus, rotation of first spur gear (323) of idler member(320) provides rotation for second spur gear (332) of second rotarymember (230). It should be understood that rotation of first spur gear(323) about fourth axis is converted into rotation of second spur gear(332) about longitudinal axis (LA) parallel with fourth axis. A CWrotation of first spur gear (323) results in CCW rotation of second spurgear (332). A CCW rotation of first spur gear (323) results in CWrotation of second spur gear (332). Other suitable ways in which secondrotary member (330) may be rotated will be apparent to those of ordinaryskill in the art in view of the teachings herein.

Rotational shaft (334) is substantially similar to drive rod (28)mentioned above in the fact that rotational shaft (334) is capable ofrotating cartridge receiving assembly (50) about bearing (24) relativeto elongated outer sheath (234). As depicted in FIG. 16, rotationalshaft (334) includes a pair of outwardly extending keys (335) that arepositioned within complementary keyways (24D) formed in a proximalcoupling feature (25) of circumferential flange (24A). Of course,rotational shaft (334) may be rotatably secured to circumferentialflange (24A) in any other suitable fashion as will be apparent to thoseskilled in the art in view of the teachings herein. It should also beunderstood that the distal portion of rotational shaft (334) may beflexible like distal bendable portion (28B) of drive rod (28). Suchflexibility may prevent rotational shaft (334) from interfering withactuation of articulation joint (23). Rotational shaft (334) may stillnevertheless transfer torsional drive forces to proximal flange (24A)despite being laterally flexible. By way of example only, the distalportion of rotational shaft (334) may be configured and operable inaccordance with at least some of the teachings of U.S. Pub. No.2014/0171970, entitled “Circular Needle Applier with Articulating andRotating Shaft,” published Jun. 19, 2014, now U.S. Pat. No. 9,357,998,issued Jun. 7, 2016, the disclosure of which is incorporated byreference herein.

As can be seen in FIGS. 17A-B, the distal end of elongated outer sheath(234) is fixed to knuckle (23A) of articulation joint (23). As mentionedabove, knuckle (23A) is pivotably coupled to bearing supports (24B, 24C)to provide articulation of cartridge receiving assembly (50) andcartridge (30) relative to the longitudinal axis (LA) of shaft assembly(150). Bearing supports (24B, 24C) allow circumferential flange (24A) torotate relative to bearing supports (24B, 24C), about the longitudinalaxis (LA) of shaft assembly (150). Also as mentioned above,circumferential flange (24A) is capable of rotating cartridge receivingassembly (50). Therefore, rotation of rotational shaft (334) rotatescircumferential flange (24A), cartridge receiving assembly (50), andcartridge (150) about longitudinal axis (LA) of shaft assembly (150),without rotating articulation joint (23) or elongated outer sheath(234). However, it should be noted that rotational shaft (334) is notsimilar to drive rod (28) in that rotational shaft (334) is not capableof actuating needle applier cartridge (30). That function is designatedto needle drive (400) as described in greater detail below.

FIGS. 17A-B shows the ultimate result of rotating drive disc (120 b) ofcartridge receiving assembly rotation drive (300). Rotation of drivedisc (120 b) rotates drive shaft (350) and first bevel gear (312).Rotation of first bevel gear (312) in turn rotates second bevel gear(322) and first spur gear (323) in the same direction and about the sameaxis. First spur gear (323) then rotates second spur gear (332) about aseparate, parallel axis in the opposite angular direction. Rotationalshaft (334) rotates about the same axis and same direction of secondspur gear (232), thereby rotating cartridge receiving assembly (50) andcartridge (30) about the longitudinal axis (LA) of shaft assembly (150).

D. Exemplary Needle Drive Components

As shown in FIG. 18, needle drive (400) comprises a drive disc (120 c),a drive shaft (450), a rotational member (410), and a translation member(430). Rotational member (410) includes a coupling shaft (414) unitarilyfixed to a pinion (412). Coupling shaft (414) and pinion (412) togetherdefine a bore (411). However, it should be noted that coupling shaft(414) alone may define bore (411). Bore (411) is dimensioned to receivedrive shaft (450) through an interference fit so that rotational member(410) and drive shaft (450) are unitarily fixed together. Of course, anyother means of fixing drive shaft (250) to first rotary member (210) maybe used, such as welding. It should be understood that rotation of drivedisc (120 c) also provides rotation to drive shaft (450) and pinion(412).

Translation member (430) includes a translating rod (434) and a rack(431). Translating rod (434) coaxially extends through both hollowportion (331) and circumferential flange (24A) along the longitudinalaxis (LA) of shaft assembly (150). Translating rod (434) is slidablydisposed within hollow portion (331) of rotational shaft (334). Distalend of translating rod (434) includes distal bendable portion (28B)coupled to mount (49). Therefore, translating rod (434) is capable ofactuating needle applier cartridge (30) as shown in FIGS. 5A-5C, as doneby drive rod (28) in the earlier example above. It should be noted thatwhile drive rod (28) is capable of both actuating needle appliercartridge (30) and rotating cartridge receiving assembly (50), thesefunctions are separately allocated among needle drive (400) andcartridge receiving assembly rotation drive (300) respectively, in thepresent example. Therefore, while distal bendable portion (28B) andproximal drive portion (28A) are fixed to each other on drive rod (28),they are separate from one another and are thus capable of independentmovement from one another in drive assembly interface (100).

Rack (431) is fixed to translating rod (434). Therefore, linear movementof rack (431) creates linear movement of translating rod (434). Teeth ofrack (431) mesh with teeth of pinion (412). Thus, rotation of pinion(412) provides linear movement of rack (431) along the longitudinal axis(LA) of shaft assembly (150). Rotation of drive disc (120 c) rotatesdrive shaft (450) and pinion (412). It should be understood thatrotation of pinion (412) occurs on a fifth axis defined by drive shaft(450), which is orthogonal with the longitudinal axis (LA) of shaftassembly (150). CW rotation of pinion (412) creates proximal translationof rack (431) and translating rod (434). CCW rotation of pinion (412)creates distal translation of rack (431) and translating rod (434).Therefore, as pinion (412) switches directions of rotation, translatingrod (434) switches direction of translation along the longitudinal axis(LA) of shaft assembly (150), making needle driver (86) capable of adrive stroke and a return stroke as shown in FIGS. 5A-5C. Other suitableways to create a drive stroke and a return stroke will be apparent tothose of ordinary skill in the art in view of the teachings herein.

In some exemplary alternative versions, translating rod (434) androtational shaft (334) are coupled together such that translating rod(434) will rotate with rotational shaft (334); yet such that translatingrod (434) may rotate relative to rotational shaft (334). Thus, whenrotational shaft (334) is driven to rotate as described above, suchrotation may be communicated to cartridge receiving assembly (50) viatranslating rod (434); and translating rod (434) may still freelyactuate needle applier cartridge (30) without interference fromrotational shaft (334). By way of example only, translating rod (434)and rotational shaft (334) may be coupled together in a key-keywayrelationship.

As another merely illustrative example, the distal portion of shaftassembly (150) may include a sliding key coupled cable connector, whichcould be located within outer sheath (234) at a location that is distalto drive assembly interface (100). Such a connector may enabletranslating rod (434) and rotational shaft (334) to each independentlyinduce motion on a single distal drive cable. For instance, ifrotational shaft (334) is actuated and translating rod (434) is heldstationary, this will rotate the distal drive cable and thereby rotatecartridge receiving assembly (50). If translating rod (434) is actuatedand rotational shaft (334) is held stationary, this will actuate needleapplier cartridge (30). Other suitable configurations and relationshipswill be apparent to those of ordinary skill in the art in view of theteachings herein.

E. Exemplary Articulation Drive Components

As shown in FIG. 19, articulation drive (500) includes a drive disc (120d), a drive shaft (550), a rotational member (510), an articulation base(530), and articulation rods (560, 570). Rotational member (510)includes a coupling shaft (514) unitarily fixed to first spur gear(512). Coupling shaft (514) extends through aperture (110). Couplingshaft (514) and first spur gear (512) together define a bore (511).However, it should be noted that coupling shaft (514) alone may definebore (511). Bore (511) is dimensioned to receive drive shaft (450)through an interference fit so that rotational member (510) and driveshaft (550) are unitarily fixed together. Of course, any other means offixing drive shaft (550) to rotational member (510) may be used, such aswelding. It should be understood that rotation of drive disc (120 d)also provides rotation to drive shaft (510) and first spur gear (512).

Articulation base (530) includes a second spur gear (532), a cam feature(535), and a post (538) extending from the face of base plate (116).Second spur gear (532) is rotatable supported on post (538). First spurgear (512) meshes with second spur gear (532) so that rotation of firstspur gear (512) rotates second spur gear (532) and cam feature (535)about post (538). Rotation of drive disc (120 d) thus also providesrotation of second spur gear (532) and cam feature (535). It should beunderstood that rotation of first spur gear (512) about a sixth axisdefined by drive shaft (550) is converted in rotation of second spurgear (532) about a seventh axis defined by post (538) that is parallelwith the sixth axis. A CW rotation of first spur gear (512) results in aCCW rotation of second spur gear (532). A CCW rotation of first spurgear (512) results in a CCW rotation of second spur gear (532). Othersuitable ways in which second spur gear (532) may be rotated will beapparent to those of ordinary skill in the art in view of the teachingsherein.

Post (538) receives the center of second spur gear (532) so that secondspur gear (532) may rotate about the seventh axis. Cam feature (535) isunitarily fixed to second spur gear (532) such that cam feature (535)rotates with second spur gear (532) about the seventh axis defined bypost (538). Cam feature (535) includes two slots (536, 537) laterallyspaced from the seventh axis. Articulation rods (560, 570) includelongitudinal members (561, 571) and transverse members (563, 573)respectively. Transverse members (563, 573) are inserted into respectiveslots (536, 537), such that transverse members (563, 573) are configuredand positioned to serve as cam followers.

Longitudinal members (561, 571) extend through elongated outer sheath(234) and terminate in distal ends similar to the distal ends of rods(27A, 27B) mentioned above. Therefore, longitudinal members (561, 571)extend through elongated outer sheath (234), through knuckle (23A), andconnect to pins (29A, 29B) on bearing support (24C). As shown in FIG. 7,longitudinal members (561, 571) extend longitudinally through outersheath (234) along respective longitudinal axes that are parallel to yetoffset from the longitudinal axis (LA) of shaft assembly (150).

As shown in FIGS. 22A-22C, rotation of cam feature (535) will opposinglypush and pull actuations rods (560, 570) due to slots (536, 537) beinglaterally spaced from the seventh axis defined by post (538). In otherwords, cam feature (535) is operable to drive actuation rods (560, 570)at the same time in opposite longitudinal directions, such thatactuation rod (560) will translate distally while actuation rod (570)translates proximally; and such that actuation rod (570) will translatedistally while actuation rod (560) translates proximally. Because pins(29A, 29B) are laterally spaced from the pivoting axis, the simultaneouspush and pull action will in turn articulate cartridge receivingassembly (50) about joint (23) relative to elongated outer sheath (234)as shown in FIGS. 23A-23C. In particular, rotating spur gear (532) CCWfrom the position shown in FIG. 22A to the position shown in FIG. 22Bwill result in cartridge receiving assembly (50) and cartridge assembly(30) being deflected laterally away to the left of the longitudinal axis(LA) of shaft assembly (150) at articulation joint (23), as shown in thetransition from FIG. 23A to FIG. 23B. Similarly, rotating spur gear(532) CW from the position shown in FIG. 22A to the position shown inFIG. 22C will result in cartridge receiving assembly (50) and cartridgeassembly (30) being deflected laterally away to the right of thelongitudinal axis (LA) of shaft assembly (150) at articulation joint(23), as shown in the transition from FIG. 23A to FIG. 23C.

III. Exemplary Combinations

The following examples relate to various non-exhaustive ways in whichthe teachings herein may be combined or applied. It should be understoodthat the following examples are not intended to restrict the coverage ofany claims that may be presented at any time in this application or insubsequent filings of this application. No disclaimer is intended. Thefollowing examples are being provided for nothing more than merelyillustrative purposes. It is contemplated that the various teachingsherein may be arranged and applied in numerous other ways. It is alsocontemplated that some variations may omit certain features referred toin the below examples. Therefore, none of the aspects or featuresreferred to below should be deemed critical unless otherwise explicitlyindicated as such at a later date by the inventors or by a successor ininterest to the inventors. If any claims are presented in thisapplication or in subsequent filings related to this application thatinclude additional features beyond those referred to below, thoseadditional features shall not be presumed to have been added for anyreason relating to patentability.

Example 1

A surgical instrument comprising: (a) a cartridge receiving assembly,wherein the cartridge receiving assembly is operable to receive a needledriving cartridge; (b) a shaft assembly, wherein the shaft assemblydefines a longitudinal axis, wherein the shaft assembly comprises: (i) adistal end, wherein the cartridge receiving assembly is positioned atthe distal end of the shaft assembly, (ii) a proximal end, and (iii) afirst actuation member, wherein the first actuation member is operableto actuate the cartridge receiving assembly to thereby drive a needlefrom a needle driving cartridge received in the cartridge receivingassembly; and (c) an interface assembly positioned at the proximal endof the shaft assembly, the interface assembly comprising: (i) a base,and (ii) a plurality of drive shafts extending upwardly from the base,wherein the drive shafts extend along respective axes that areperpendicular to the longitudinal axis of the shaft assembly, whereinthe drive shafts are rotatable independently relative to each other,wherein a first drive shaft of the plurality of drive shafts is operableto drive the first actuation member.

Example 2

The surgical instrument of Example 1, wherein the first actuation membercomprises a longitudinally extending shaft, wherein the longitudinallyextending shaft is operable to translate longitudinally along thelongitudinal axis of the shaft assembly to thereby actuate the cartridgereceiving assembly.

Example 3

The surgical instrument of Example 2, wherein the first actuation memberfurther comprises a rack secured to the longitudinally extending shaft,wherein the first drive shaft is operable to rotate a pinion, whereinthe pinion is coupled with the rack such that the longitudinallyextending shaft is configured to translate longitudinally along thelongitudinal axis of the shaft assembly in response to rotation of thefirst drive shaft.

Example 4

The surgical instrument of any one or more of Examples 1 through 3,wherein the shaft assembly further comprises an articulation joint,wherein the articulation joint is operable to deflect the cartridgereceiving assembly laterally away from the longitudinal axis of theshaft assembly.

Example 5

The surgical instrument of Example 4, wherein the shaft assembly furthercomprises at least one articulation drive member, wherein the at leastone articulation drive member is configured to translate longitudinallyto actuate the articulation joint to thereby deflect the cartridgereceiving assembly laterally away from the longitudinal axis of theshaft assembly.

Example 6

The surgical instrument of Example 5, wherein the plurality of driveshafts further comprises a second drive shaft coupled with the at leastone articulation drive member, wherein the second drive shaft isoperable cause the at least one articulation drive member to translatelongitudinally in response to rotation of the second drive shaft.

Example 7

The surgical instrument of Example 6, wherein the interface assemblyfurther comprises a pair of spur gears coupling between the second driveshaft with the articulation drive member.

Example 8

The surgical instrument of Example 7, wherein a first spur gear of thepair of spur gears comprises a cam feature, wherein the articulationdrive member comprises a cam follower engaged with the cam feature ofthe first spur gear.

Example 9

The surgical instrument of any one or more of Examples 6 through 7,wherein the at least one articulation member comprises a firstarticulation drive member and a second articulation drive member,wherein the first and second articulation drive members are operable totranslate longitudinally in opposing directions simultaneously tothereby deflect the cartridge receiving assembly laterally away from thelongitudinal axis of the shaft assembly.

Example 10

The surgical instrument of Example 9, wherein the second drive shaft isoperable cause the first and second articulation drive members totranslate longitudinally in opposing directions simultaneously inresponse to rotation of the second drive shaft.

Example 11

The surgical instrument of any one or more of Examples 1 through 10,wherein the shaft assembly further comprises: (i) an outer sheath, and(ii) a second actuation member, wherein the second actuation member isoperable to rotate the cartridge receiving assembly independently of theouter sheath about the longitudinal axis of the shaft assembly.

Example 12

The surgical instrument of Example 11, wherein the wherein the pluralityof drive shafts further comprise a second drive shaft operable to drivethe second actuation member.

Example 13

The surgical instrument of any one or more of Examples 1 through 12,wherein the shaft assembly further comprises: (i) an outer sheath, and(ii) an articulation joint, wherein the articulation joint is operableto deflect the cartridge receiving assembly laterally away from thelongitudinal axis of the shaft assembly.

Example 14

The surgical instrument of Example 13, wherein the outer sheath isrotatable about the longitudinal axis of the shaft assembly, wherein thearticulation joint is configured to rotate with the outer sheath aboutthe longitudinal axis of the shaft assembly independently of thecartridge receiving assembly.

Example 15

The surgical instrument of Example 14, wherein the wherein the pluralityof drive shafts further comprise a second drive shaft operable to rotatethe outer sheath and the articulation joint together about thelongitudinal axis of the shaft assembly.

Example 16

The surgical instrument of any one or more of Examples 1 through 15,further comprising a needle driving cartridge received in the cartridgereceiving assembly.

Example 17

The surgical instrument of Example 16, wherein the needle drivingcartridge comprises: (i) a curved needle, (ii) a length of suturesecured to the curved needle, and (iii) a needle drive assembly operableto drive the curved needle along an orbital path, wherein the firstactuation member is operable to actuate the needle drive assembly.

Example 18

The surgical instrument of Example 17, wherein the needle drive assemblyof the needle driving cartridge is operable to drive the curved needlealong an orbital path that encircles an axis that is non-parallel withthe longitudinal axis of the shaft assembly.

Example 19

A surgical instrument comprising: (a) a curved needle; (b) a length ofsuture secured to the curved needle; (c) a needle drive assemblyoperable to drive the curved needle along an orbital path; (d) a shaftassembly, wherein the shaft assembly defines a longitudinal axis,wherein the shaft assembly comprises: (i) a distal end, wherein theneedle drive assembly is positioned at the distal end of the shaftassembly, (ii) a proximal end, and (iii) an actuation member, whereinthe actuation member is operable to actuate the needle drive assembly tothereby drive the needle along the orbital path; and (e) an interfaceassembly positioned at the proximal end of the shaft assembly, theinterface assembly comprising: (i) a base, and (ii) a plurality of driveshafts extending upwardly from the base, wherein the drive shafts extendalong respective axes that are perpendicular to the longitudinal axis ofthe shaft assembly, wherein the drive shafts are rotatable independentlyrelative to each other, wherein a first drive shaft of the plurality ofdrive shafts is operable to drive the actuation member.

Example 20

A surgical instrument comprising: (a) a cartridge receiving assembly,comprising: (i) a first jaw, and (ii) a second jaw pivotable relative tothe first jaw from an open position to a closed position, wherein theclosed position is configured to hold a needle driving cartridge betweenthe first jaw and the second jaw; (b) a shaft assembly, wherein theshaft assembly defines a longitudinal axis, wherein the shaft assemblycomprises: (i) a distal end, wherein the cartridge receiving assembly ispositioned at the distal end of the shaft assembly, (ii) a proximal end,and (iii) a first actuation member, wherein the first actuation memberis operable to actuate the cartridge receiving assembly to thereby drivea needle from a needle driving cartridge received in the cartridgereceiving assembly; and (c) an interface assembly positioned at theproximal end of the shaft assembly, the interface assembly comprising:(i) a base, and (ii) a plurality of drive shafts extending upwardly fromthe base, wherein the drive shafts extend along respective axes that areperpendicular to the longitudinal axis of the shaft assembly, whereinthe drive shafts are rotatable independently relative to each other,wherein a first drive shaft of the plurality of drive shafts is operableto drive the first actuation member.

IV. Miscellaneous

It should also be understood that any one or more of the teachings,expressions, embodiments, examples, etc. described herein may becombined with any one or more of the other teachings, expressions,embodiments, examples, etc. that are described herein. Theabove-described teachings, expressions, embodiments, examples, etc.should therefore not be viewed in isolation relative to each other.Various suitable ways in which the teachings herein may be combined willbe readily apparent to those of ordinary skill in the art in view of theteachings herein. Such modifications and variations are intended to beincluded within the scope of the claims.

It should be appreciated that any patent, publication, or otherdisclosure material, in whole or in part, that is said to beincorporated by reference herein is incorporated herein only to theextent that the incorporated material does not conflict with existingdefinitions, statements, or other disclosure material set forth in thisdisclosure. As such, and to the extent necessary, the disclosure asexplicitly set forth herein supersedes any conflicting materialincorporated herein by reference. Any material, or portion thereof, thatis said to be incorporated by reference herein, but which conflicts withexisting definitions, statements, or other disclosure material set forthherein will only be incorporated to the extent that no conflict arisesbetween that incorporated material and the existing disclosure material.

Versions of the devices described above may have application inconventional medical treatments and procedures conducted by a medicalprofessional, as well as application in robotic-assisted medicaltreatments and procedures. By way of example only, various teachingsherein may be readily incorporated into a robotic surgical system suchas the DAVINCI™ system by Intuitive Surgical, Inc., of Sunnyvale, Calif.

Versions described above may be designed to be disposed of after asingle use, or they can be designed to be used multiple times. Versionsmay, in either or both cases, be reconditioned for reuse after at leastone use. Reconditioning may include any combination of the steps ofdisassembly of the device, followed by cleaning or replacement ofparticular pieces, and subsequent reassembly. In particular, someversions of the device may be disassembled, and any number of theparticular pieces or parts of the device may be selectively replaced orremoved in any combination. Upon cleaning and/or replacement ofparticular parts, some versions of the device may be reassembled forsubsequent use either at a reconditioning facility, or by a userimmediately prior to a procedure. Those skilled in the art willappreciate that reconditioning of a device may utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

By way of example only, versions described herein may be sterilizedbefore and/or after a procedure. In one sterilization technique, thedevice is placed in a closed and sealed container, such as a plastic orTYVEK bag. The container and device may then be placed in a field ofradiation that can penetrate the container, such as gamma radiation,x-rays, or high-energy electrons. The radiation may kill bacteria on thedevice and in the container. The sterilized device may then be stored inthe sterile container for later use. A device may also be sterilizedusing any other technique known in the art, including but not limited tobeta or gamma radiation, ethylene oxide, or steam.

Having shown and described various embodiments of the present invention,further adaptations of the methods and systems described herein may beaccomplished by appropriate modifications by one of ordinary skill inthe art without departing from the scope of the present invention.Several of such potential modifications have been mentioned, and otherswill be apparent to those skilled in the art. For instance, theexamples, embodiments, geometrics, materials, dimensions, ratios, steps,and the like discussed above are illustrative and are not required.Accordingly, the scope of the present invention should be considered interms of the following claims and is understood not to be limited to thedetails of structure and operation shown and described in thespecification and drawings.

We claim:
 1. A surgical instrument comprising: (a) a cartridge receivingassembly, wherein the cartridge receiving assembly is operable toreceive a needle driving cartridge; (b) a shaft assembly, wherein theshaft assembly defines a longitudinal axis, wherein the shaft assemblycomprises: (i) a distal end, wherein the cartridge receiving assembly ispositioned at the distal end of the shaft assembly, (ii) a proximal end,and (iii) a first actuation member, wherein the first actuation memberis operable to actuate the cartridge receiving assembly to thereby drivea needle from a needle driving cartridge received in the cartridgereceiving assembly and wherein the shaft assembly further comprises: (i)an outer sheath, and (ii) a second actuation member, wherein the secondactuation member is operable to rotate the cartridge assemblyindependently of the outer sheath about the longitudinal axis of theshaft assembly; and (c) an interface assembly positioned at the proximalend of the shaft assembly, the interface assembly comprising: (i) abase, and (ii) a plurality of drive shafts extending upwardly from thebase, wherein the drive shafts extend along respective axes that areperpendicular to the longitudinal axis of the shaft assembly, whereinthe drive shafts are rotatable independently relative to each other,wherein a first drive shaft of the plurality of drive shafts is operableto drive the first actuation member, wherein the plurality of driveshafts further comprises a second drive shaft operable to drive thesecond actuation member.
 2. The surgical instrument of claim 1, whereinthe first actuation member comprises a longitudinally extending shaft,wherein the longitudinally extending shaft is operable to translatelongitudinally along the longitudinal axis of the shaft assembly tothereby actuate the cartridge receiving assembly.
 3. The surgicalinstrument of claim 2, wherein the first actuation member furthercomprises a rack secured to the longitudinally extending shaft, whereinthe first drive shaft is operable to rotate a pinion, wherein the pinionis coupled with the rack such that the longitudinally extending shaft isconfigured to translate longitudinally along the longitudinal axis ofthe shaft assembly in response to rotation of the first drive shaft. 4.The surgical instrument of claim 1, wherein the shaft assembly furthercomprises an articulation joint, wherein the articulation joint isoperable to deflect the cartridge receiving assembly laterally away fromthe longitudinal axis of the shaft assembly.
 5. The surgical instrumentof claim 4, wherein the shaft assembly further comprises at least onearticulation drive member, wherein the at least one articulation drivemember is configured to translate longitudinally to actuate thearticulation joint to thereby deflect the cartridge receiving assemblylaterally away from the longitudinal axis of the shaft assembly.
 6. Thesurgical instrument of claim 5, wherein the plurality of drive shaftsfurther comprises the second drive shaft coupled with the at least onearticulation drive member, wherein the second drive shaft is operable tocause the at least one articulation drive member to translatelongitudinally in response to rotation of the second drive shaft.
 7. Thesurgical instrument of claim 6, wherein the interface assembly furthercomprises a pair of spur gears coupling between the second drive shaftwith the articulation drive member.
 8. The surgical instrument of claim7, wherein a first spur gear of the pair of spur gears comprises a camfeature, wherein the articulation drive member comprises a cam followerengaged with the cam feature of the first spur gear.
 9. The surgicalinstrument of claim 6, wherein the at least one articulation membercomprises a first articulation drive member and a second articulationdrive member, wherein the first and second articulation drive membersare operable to translate longitudinally in opposing directionssimultaneously to thereby deflect the cartridge receiving assemblylaterally away from the longitudinal axis of the shaft assembly.
 10. Thesurgical instrument of claim 9, wherein the second drive shaft isoperable to cause the first and second articulation drive members totranslate longitudinally in opposing directions simultaneously inresponse to rotation of the second drive shaft.
 11. The surgicalinstrument of claim 1, wherein the shaft assembly further comprises: (i)the outer sheath, and (ii) an articulation joint, wherein thearticulation joint is operable to deflect the cartridge receivingassembly laterally away from the longitudinal axis of the shaftassembly.
 12. The surgical instrument of claim 11, wherein the outersheath is rotatable about the longitudinal axis of the shaft assembly,wherein the articulation joint is configured to rotate with the outersheath about the longitudinal axis of the shaft assembly independentlyof the cartridge receiving assembly.
 13. The surgical instrument ofclaim 12, wherein the plurality of drive shafts further comprise thesecond drive shaft operable to rotate the outer sheath and thearticulation joint together about the longitudinal axis of the shaftassembly.
 14. The surgical instrument of claim 1, further comprising aneedle driving cartridge received in the cartridge receiving assembly.15. The surgical instrument of claim 14, wherein the needle drivingcartridge comprises: (i) a curved needle, (ii) a length of suturesecured to the curved needle, and (iii) a needle drive assembly operableto drive the curved needle along an orbital path, wherein the firstactuation member is operable to actuate the needle drive assembly. 16.The surgical instrument of claim 15, wherein the needle drive assemblyof the needle driving cartridge is operable to drive the curved needlealong an orbital path that encircles an axis that is non-parallel withthe longitudinal axis of the shaft assembly.
 17. A surgical instrumentcomprising: (a) a cartridge receiving assembly, comprising: (i) a firstjaw, and (ii) a second jaw pivotable relative to the first jaw from anopen position to a closed position, wherein the closed position isconfigured to hold a needle driving cartridge between the first jaw andthe second jaw; (b) a shaft assembly, wherein the shaft assembly definesa longitudinal axis, wherein the shaft assembly comprises: (i) a distalend, wherein the cartridge receiving assembly is positioned at thedistal end of the shaft assembly, (ii) a proximal end, and (iii) a firstactuation member, wherein the first actuation member is operable toactuate the cartridge receiving assembly to thereby drive a needle froma needle driving cartridge received in the cartridge receiving assembly;and (c) an interface assembly positioned at the proximal end of theshaft assembly, the interface assembly comprising: (i) a base, and (ii)a plurality of drive shafts extending upwardly from the base, whereinthe drive shafts extend along respective axes that are perpendicular tothe longitudinal axis of the shaft assembly, wherein the drive shaftsare rotatable independently relative to each other, wherein a firstdrive shaft of the plurality of drive shafts is operable to drive thefirst actuation member.